2

MACHINE SAFETY PRODUCTS 2003

MACHINE
SAFETY
PRODUCTS

BANNER ENGINEERING CORPORATION

9714 10TH AVENUE NORTH MINNEAPOLIS, MINNESOTA 55441 (763) 544-3164 FAX (763) 544-3213
1-888-3-SENSOR (1-888-373-6767) www.bannerengineering.com Email: sensors@bannerengineering.com
P/N 69800

PRINTED IN USA

where

can you

instantly access
the largest library of

sensing
information in the

world?
More safety & sensing

More Information

solutions online

online

Instantly download catalogs, brochures,

data sheets and more in PDF format.
Theres extensive technical reference
data, along with tutorials, tables,
glossaries and hundreds of useful links.

view & download

literature

Catalogs, brochures, data sheets

and application files are available
in multiple languages and can be
downloaded immediately or
conveniently emailed to you in
PDF format.

Our online product selector matches your needs with the right
product. Get detailed information on more than 10,000 sensing
solutions including machine safety systems and photoelectric
sensors, plus measurement and inspection products.

Applications, tutorials &

online training

Each product line includes a technical

information section with glossaries,
tutorials, tables, and a FAQ (frequently
asked questions) section. Informative
animated tutorials help users comprehend complex sensing technologies.

instant access to

More

support

Get online application engineering support

and a global distributor locator. Buy Banner
products 24/7 with overnight delivery of
most items. Browse through our extensive
library of illustrated product applications.

purchase online 24/7

autoCAD files

overnight delivery

bannerengineering.com details
the entire Banner line, complete
with downloadable technical data,
application drawings, and AutoCAD
files in DXF format.

buybanneronline.com
Allows immediate purchase of more
than 10,000 products. It is connected
to an automated fulfillment system,
allowing in-stock orders to ship
with overnight delivery.

bannerengineering.com

Table of Contents

Introduction

Extension & Interface Modules . . . . . . . . . 207

About Banner Engineering . . . . . . . . . . . . . . . 4

Muting Module

New!

. . . . . . . . . . . . . . . . 217

Whats New . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety Interlock Switches
OSHA

Machine Safeguarding Standards &

Regulations . . . . . . . . . . . . . . . . . . . . . 12
Interfacing of Satety Systems. . . . . . . . . . . . 22

Optical Safety Systems

PICO-GUARD

Hinge Style Switches

New!

Flat Pack Style Switches . . . . . . . . . . . . . . 235

Limit Style Switches

New!

. . . . . . . . . . . 229

. . . . . . . . . . . 243

. . . . . . . . . . . . . . . . . . 43
Locking Style Switches

. . . . . . . . . 261

EZ-SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Magnet Style Switches . . . . . . . . . . . . . . . . 273
MICRO-SCREEN

. . . . . . . . . . . . . . . . 71
Emergency Stop Devices

MINI-SCREEN

. . . . . . . . . . . . . . . . . 103

MACHINE-GUARD & PERIMETER-GUARD . . . 141

Safety Modules

Two-Hand-Control Modules

Emergency Stop Push Buttons

New!

. . . . 293

Appendices

. . . . . . . 165

Emergency Stop Safety Modules

. . . 181

Safety Gate Monitoring Modules

. . 197

Safety Mat Monitoring Modules

Emergency Stop Rope Pull Switches .N.ew. !. . 279

New!

. .203

A: Optical Safety Systems . . . . . . . . . . . . . . . . . . . . .298

B: Safety Modules . . . . . . . . . . . . . . . . . . . . . . . . . .346
C: Safety Interlock Switches . . . . . . . . . . . . . . . . . . .388
D: Emergency Stop Devices . . . . . . . . . . . . . . . . . . . .389
Supplemental Information

Glossary of Machine Safety Terms . . . . . . . . . . . . . . .392

Data Reference Tables . . . . . . . . . . . . . . . . . . . . . . .398
International Sales Representatives . . . . . . . . . . . . . .404
Product Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . .409

Banner Engineering Corp. Minneapolis, MN U.S.A. bannerengineering.com Tel: 763.544.3164

About Banner Engineering

Introduction

More Machine
Safeguarding
Solutions
Industrys most complete line of
safety light screens
Broad selection of safety modules
Extensive family of safety interlock
switches
More than 2,000 field sales engineers
Global support in more than 100
countries

More Sensing Solutions

Banner manufactures the industrys most complete line of photoelectric and
special-purpose sensors a sensing product for every application.
More than 15,000 sensor models
- Photoelectrics
- Lasers
- Machine vision
- Ultrasonics
- Fiber optics
Models for all sensing environments
Measurement and inspection sensors

Advanced Manufacturing

Automated cellular manufacturing

100% functional testing
Fast fulfillment of modified and special product requests
Five ultra-efficient manufacturing plants accommodate any volume
requirement
95% of orders ship within 3 days, most within hours

More Machine Safeguarding Knowledge

Factory-trained sales force

Dedicated Factory Safety Application Engineers offer support to our sales
force and to you
All products comply with global design standards
Regional Business Centers offer localized customer support

Banner Engineering Corp. Minneapolis, MN U.S.A. bannerengineering.com Tel: 763.544.3164

About Banner Engineering

Facilities That Assure Quality and High Volume Capacity.

Introduction

Banner Headquarters
Minneapolis, MN

Banner Manufacturing Plant

Minneapolis, MN

Banner Manufacturing Plant

Huron, SD

Banner Manufacturing Plant

Aberdeen, SD

Banner Manufacturing Plant

Fergus Falls, MN

Dedicated R&D Design Center

This state-of-the-art facility houses more than 100 engineers, the largest engineering
staff of its kind, to research and apply the latest optical and safety technologies,
including advanced capabilities in circuit design and software development.

Superior Applications Engineers

Banner provides the very best applications engineering; technical experts who
understand how to apply sensing and safety technology better than anyone.

The Best Team in the Field

Banners sales and distribution network is widely acknowledged as the best in our
industry. Wherever you are located, you are close to highly trained professionals who
will help you find the best sensing and safety solutions.

Banner Engineering Corp. Minneapolis, MN U.S.A. bannerengineering.com Tel: 763.544.3164

Whats New

PICO-GUARD Makes Installation of

Complete Safety Systems Incredibly Easy
ICO-GUARD is the newest and easiest way to
safeguard hazardous machines. This optically
synchronized, microcontroller-based and controlreliable photoelectric system is designed to be used
with plastic fiber optic cable and quick-connect optical
components specially designed for reliable noncontact detection.

Introduction

This revolutionary new safety system is incredibly

versatile, efficient and easy to install. It combines
various plug-on, snap-lock PICO-GUARD Fiber Optic
Safety Interlock Switches and plastic fiber optic
cable to monitor door, gate, and hard guards. And
soon, a line of pre-cabled, cut-to-length single-beam
point and multiple-beam grid array products will also
become available.
Safeguarding applications include:

ary
Revolutiontic
Fiber Op tem
Safety Sys

Monitoring machine access doors and gates

Entry/exit guarding
Short-range perimeter guarding
Multiple fiber optic beam solutions for custom
guarding applications
See page 43

Non-Contact Fiber Optic

he PICO-GUARD system is a unique combination of controlreliable photoelectric and fiber optic technologies. The
controller has four independent optical channels, each with a
pair of quick-connect (plug-in, snap-lock) fiber interface ports.

Fiber optic detection

Optical elements (Interlock Switches, Grids and Points) are
tough and sealed
No electrical energy is used at the detection points all
electronics are located in the controller
Plastic fiber optic cable is available with three types of jacketing,
depending on environmental requirements

Category 4, Type 4 Design

ICO-GUARD is designed to meet ISO 13849-1 (EN954-1)
Category 4 and IEC 61496-1 Type 4 requirements1. The heart
of the system is a patent-pending, diverse-redundant selfchecking photoelectric engine, designed specifically for use with
plastic fiber optic cable. The controllers hardware and firmware
have been extensively tested via rigorous Failure Modes and
Effects Analysis (FMEA) techniques.

P
1

Approvals Pending

Banner Engineering Corp. Minneapolis, MN U.S.A. bannerengineering.com Tel: 763.544.3164

Whats New

Designed for Efficient Safeguarding

Introduction

his compact, sleek controller is designed for fast installation. It

uses plug-on wiring terminals and easy-to-access DIP switches.
Each of the four optical channels can monitor one or more doors
or gates. The big news here is that a single switch point per door will
meet Safety Category 4 applications per ISO 13849 (EN 954-1)
(approvals pending). The controller uses redundant solid-state outputs
to switch 24V dc loads and will immediately send a stop signal to the
machine control whenever the receiver circuit of any optical channel
detects the absence of its signal, or a safety device sends a stop signal
to the USSI interface.

Other Advanced Features

Selectable External Device Monitoring (EDM)
Selectable Trip or Latch output functions
Selectable 1- to 4-channel operation
Quick-connect fiber optic cable interface
Redundant solid-state safety outputs for 24V dc loads
Optional positive-guided contactors and interface modules available
Fast response time: 13 milliseconds
Three non-safety signal outputs: Auxiliary, Weak Signal and Fault
RS-232 connection for system status and diagnostic information
Optional Remote Display

USSI (Patent Pending) for Connecting Controllers

and other Safety Devices
anners unique Universal Safety Stop Interface (USSI) allows
two or more PICO-GUARD controllers to be connected to
control a single machine when required. In addition, this novel
interface permits connections to other safety devices, such as light
screens, E-stop buttons and rope pulls, making it easy to integrate
many safety functions into one controller. Each controller has two
USSI input connections one with latching output logic and the
other with trip output logic.

Solving a Variety of Applications

ICO-GUARD optics are available in a variety of configurations to
allow easy installation and proper operation on a variety of doors
and other safety guarding applications. Fiber optic safety interlock
switches, points and grids provide multiple guarding solutions.

Fiber optic safety interlock switches are available in several

configurations to allow easy installation and proper operation on a
variety of doors and other hard guarding applications
Coming soon: Fiber Optic Safety Points single beams in both 12 mm
and 30 mm barrel format. These rugged components are sealed, with
cut-to-length plastic fiber optic cable pre-installed. These elements are
suitable for custom beam configurations and supplemental guarding
situations.
Coming soon: Fiber
Optic Safety Grids
2-, 3-, and 4-beam
arrays in rugged,
sealed, aluminum
enclosures with cut-tolength plastic fiber
optic cable. These
elements are suited for
torso detection and
have pre-set beam
spacing, based on
both IEC and ANSI/RIA
and B11 standards.

Straight Safety Interlock Switches

Fiber Optic
Safety Grid

Rugged 30 mm stainless steel Fiber Optic

Safety Point

Banner Engineering Corp. Minneapolis, MN U.S.A. bannerengineering.com Tel: 763.544.3164

Active/Passive Safety Interlock Switches

Right-Angle Safety Interlock

Switches

Whats New

Muting Module
he MM-TA-12B Muting Module monitors inputs from
sensors to determine when a car body, pallet or other
work piece needs to pass through an access point
and into a guarded work cell, without causing the
machinery to stop. This function is necessary for certain
production processes to run smoothly.

Introduction

Diverse-redundant microcontroller-based logic module

Designed to control when a system can safely mute
safety light screen outputs
Combines with the short-range
EZ-SCREEN Grid to provide a complete
package for guarding entry/exit points
anywhere work-in-process needs to flow
freely into and out of hazardous work cells
or areas
Uses inputs from sensors and switches
determine if the light screen obstruction is a
work piece or a person
Rugged IP65 construction allows easy installation in or near the guarded area without an enclosure
All connections made via standard quick-disconnect cables
See page 217

MINI-SCREEN HD Heavy-Duty
Light Screens
ew rugged-duty MINI-SCREEN HD series
emitters and receivers include a heavy duty
housing and new flexible mounting options. In
this enclosure, the MINI-SCREEN can now guard a full
6' (1829 mm) defined area.

N
4

Defined areas from 24" to 72" (610 mm to 1829 mm)

Rectangular design with swivel bracket at each end
Mounting channel on each side of housing for
additional mounting flexibility
Rugged, long-range solution operates at up to
18 m (60')
38 mm (1.5") minimum object size sensitivity
Highly immune to ambient light
See pages 109 and 110

Latch/Trip Output Selectable Controller

ew MINI-SCREEN controllers allow users to easily select between a latch output,
requiring manual reset, and a trip output that automatically resets the system
when the object is removed.

Models with or without External Device Monitor input for back-checking MPCEs
Easily configured for Floating Blanking (two-beam) and Auto Power-Up
See page 112

Banner Engineering Corp. Minneapolis, MN U.S.A. bannerengineering.com Tel: 763.544.3164

Whats New

Tough Enclosures for EZ-SCREEN Light Screens

and Mirrors
Introduction

hese rugged, floor-standing enclosures house

EZ-SCREEN Point and Grid light screens or mirrors for
guarding single-plane and multi-sided applications.

Tough, powder-coated extruded aluminum body and

anodized aluminum top and base plates
12 models available: 5 with corner mirrors, 2 with return
45 mirrors for access guarding applicatons; 5 to house
EZ-SCREEN Point and Grid sensors
Mirrors are independently adjustable
Rear-surface glass mirrors are rated at 85% efficiency,
allowing 2-, 3-, or 4-sided guarding
Leveling screws and bubble-level make installation easy
See page 65

Washdown-Safe Light Screen Enclosures and Corner Mirrors

ew water-tight enclosures constructed of FDA-grade polycarbonate
withstand high-pressure washdown applications in all FDA
environments. Stainless steel mirrors allow FDA-compliant multi-sided
guarding.

Washdown-safe enclosures for MINI-SCREEN light screens

Rated NEMA 4X, IP66
Includes stainless steel mounting components
12 models for guarding defined areas from 114 mm to 1219 mm (4.5" to 48")
Minimum object detection size from 28 mm to 33 mm (1.1" to 1.3"),
depending on model
Polished stainless steel mirrors provide reflectivity which is similar to
glass mirrors
See page 134

AC DUO-TOUCH Two-Hand Controls

ew AC two-hand logic modules are now available for
plants and applications requiring 115V ac or 220V ac
power. They function with Banners existing STB selfchecking touch buttons (or other similar devices) to create a
complete, ergonomic two-hand-control system.

Diverse-redundant microcontroller circuit and two

redundant, force-guided (positive-guided) output contacts
Anti-tiedown logic requires both touch buttons to be
activated within one-half second of each other
Safety Category 4 per ISO 13849-1(EN 954-1), and is a
functional Type IIIC two-hand-control per EN 574 (pending)
STB touch buttons are a major ergonomic improvement
over mechanical and difficult-to-activate capacitive buttons
Versions with muting function available soon
See pages 166 and 168

Banner Engineering Corp. Minneapolis, MN U.S.A. bannerengineering.com Tel: 763.544.3164

Whats New

Hinge-Style Safety Interlock Switches

hese unique safety switches are integrated and
encapsulated into a load-bearing hinge to provide
a high degree of protection from tampering. All
switch components are concealed inside the hinge to
provide exceptional protection from mechanical impact.

Introduction

Superior performance to actuator-activated safety

switches, rated IEC IP67
Positive-opening safety contacts (IEC 60947-5-1)
no springs to break
Identical in appearance to non-safety hinge
Achieve Category 1 (one hinge) or Category 4 (two
hinges) when used with appropriate controller
180 travel with guard-closed position adjustable
over full range
Use for hinged machine covers, doors, fences, etc.
See page 229

Heavy-Duty Rope-Pull E-Stop Switches

ew heavy-duty models allow workers to shut
down machinery along spans up to a 75 m (245')
span saving critical time and product loss in
emergency situations.

42 mm housing design with positive-opening safety

contacts per IEC 60947-5-1
Not dependent on springs; contacts latch open when
rope is pulled, requiring manual reset
IP67 and NEMA 4 rated, heavy-duty diecast metal
housing for demanding industrial applications
Two styles: standard eyebolt, or model with integral
turnbuckle and clamp for easy rope tensioning
Extra contacts allow monitoring or a dual-channel
input to a safety device
Rated to one million mechanical operations
See page 279

E-Stop Push Buttons

ew 22 mm push-to-stop, twist-to-release
mechanical push buttons.

Latching design, ISO 13850 (EN418) compliant

Available components include station
enclosures, contact elements and disk labels
See page 293

10

Banner Engineering Corp. Minneapolis, MN U.S.A. bannerengineering.com Tel: 763.544.3164

Whats New

Emergency Stop Safety Modules

anner offers a full line of readily-available
emergency stop safety modules. New upgraded
models ES-UA-5A and ES-VA-5A add additional
features to existing ES-GA-5A and ES-HA-5A models.

Introduction

Auxiliary normally closed contact with 6 amp

capability (K1 and K2 contacts in parallel)
12-24V dc/115V ac or 12-24V dc/230V ac power
supply
New housing with Banners convenient pluggable
terminal blocks
High repeatability and reliability when used with tripoutput safety light screens
See page 186

Adjustable Delay Safety Modules

anner has upgraded existing ES-TN-1H.. safety modules with additional contacts and a smaller housing than
competitive designs.

ES-TN-14H5 features adjustable delay of 0-20 seconds, 4 N/O-immediate and 4 N/O-delayed

channels
ES-TN-14H6 features adjustable delay of 0-200 seconds, 4 N/C-immediate and 4 N/C-delayed
channels
Contacts rated at 4A
Removable terminal blocks
All other functionality is the same as the ES-TN-1H.. models
See page 190

Safety Mat Monitor Module

hese new monitor modules can be used with any
standard, 4-wire safety mat or safety edge that is
based on contact plates or strips that short to
cause activation (not for fiber optic mats).

Diverse-redundant, microprocessor-based design

meets Safety Category 4 per ISO 13849-1 (EN 954-1)
plus UL991 and ISO 13850 (EN 418)
Four redundant, forced-guided (positive-guided)
output contacts rated at 6A
Can monitor multiple mats connected in series
Selectable Auto Reset or Monitored Manual Reset
Normally-closed output for status monitoring
Auxiliary solid-state outputs indicate state of internal
relays and power supply
DIN-rail-mountable 45 mm-wide housing
See page 203

Banner Engineering Corp. Minneapolis, MN U.S.A. bannerengineering.com Tel: 763.544.3164

11